Toe link support and method of supporting a toe link

ABSTRACT

A toe link support is disclosed. In a first aspect, the toe link aperture of a hub has been bored out to receive inner and outer spacers. The spacers have bolt holes through which a toe link bolt is inserted to secure a toe link to the hub. The bolt is secured by a nut. The spacers protect the hub from damage by the bolt, and vice versa, resulting from motion of the toe link. In a second aspect, the outer spacer is further configured to be inserted into the bolt hole of the toe link, further protecting the bolt from damage. A method of supporting a toe link is also disclosed.

CROSS REFERENCE TO RELATED APPLICATION [S]

This application is a divisional of U.S. Patent Application to JustinSmith entitled “TOE LINK SUPPORT AND METHOD OF SUPPORTING A TOE LINK,”U.S. Ser. No. 16/228,463, filed Dec. 20, 2018 which claims priority toU.S. Provisional Patent Application to Justin Smith entitled: “TOE LINKSUPPORT AND METHOD OF SUPPORTING A TOE LINK,” Ser. No. 62/742,062, filedOct. 5, 2018, the disclosure of which is hereby incorporated entirelyherein by reference.

BACKGROUND OF THE INVENTION Technical Field

This invention relates generally to vehicle suspension systems andparticularly to a support for a toe link.

State of the Art

A conventional hub of a vehicle suspension system comprises a toe linkaperture with a relative diameter corresponding to the diameter of a toelink bolt inserted therethrough. Conventional toe link bolts are insingle shear, with forces in the toe link bolt, resulting from movementof the toe link acting on the toe link bolt, being counteracted only bycontact of the toe link bolt with the hub at the inner surface of thetoe link aperture. This often results in the toe link aperture beingworn out or wallowed out by contact with the toe link bolt, leaving thetoe link aperture out-of-round. The toe link bolt is often thereby leftfitting loosely in the toe link aperture. The toe link bolt is alsocommonly damaged thereby by bending or breaking. Often, a hub may befurther damaged by contact with the toe link and/or by contact with thenut. The hub may be made of a metal that is subject to bending, or suchdamage as described above by contact with a toe link or a toe link boltor nut, such as aluminum, for example.

Accordingly, what is needed is a toe link support that reduces damage tothe hub or the toe link bolt.

SUMMARY OF THE INVENTION

The present invention relates generally to vehicle suspension systemsand particularly to a support for a toe link.

In embodiments of the present invention, a toe link support comprises aninner spacer and an outer spacer. The inner and outer spacers may be ofsubstantially cylindrical shape, each spacer being configured with aflange about one end thereof. The inner and outer spacers are insertedinto the toe link aperture of a hub, such that insertion depth of theinner and outer spacers is limited by engagement of the flanges thereofwith the hub. Each of the inner and outer spacers further comprises alongitudinal aperture therethrough, the aperture being configured toreceive a toe link bolt therethrough.

In embodiments, a toe link bolt may be inserted through an aperture in arod end, through the apertures of the outer and inner spacers, andsecured by a nut. In such embodiments, the hub is protected from contactwith the nut by the inner spacer and the flange thereof. The hub issimilarly protected from contact with the rod end by the outer spacerand the flange thereof. The hub is also protected from contact with thetoe link bolt by the inner and outer spacers. The hub and the toe linkbolt are thereby protected, by the inner and outer spacers, from damageresulting from motion of the rod end.

In some embodiments, a second end of the outer spacer extends beyond theflange, wherein the flange is disposed about a middle portion thereofsuch that the outer spacer may also be inserted into an aperture of therod end. Thereby a first end of the outer spacer may be inserted intothe toe link aperture of the hub and the second end of the outer spacermay be inserted into the aperture of the rod end, wherein the insertiondepth of the first end into the toe link aperture of the hub is limitedby engagement of the flange with the hub and the insertion depth of thesecond end into the aperture of the rod end is limited by engagement ofthe flange with the rod end. In addition, the flange has a taperedportion extending therefrom toward the second end. In such embodiments,the rod end may be configured to be fitted with inner and outer highmisalignment spacers, the outer high misalignment spacer being insertedinto the aperture of the rod end from the outer side of the rod end, andthe second end of the outer spacer being inserted into the aperture ofthe rod end from the inner side of the rod end. In such embodiments, theinner high misalignment spacer is discarded, having been replaced by thesecond end of the outer spacer. The tapered portion of the flangethereby separates the rod end from the hub to allow freedom of motion ofthe rod end, thus preventing contact of the rod end with the outermostedge of the flange and the hub.

Also disclosed is a method of supporting a toe link comprising: boringthe toe link aperture of a hub; inserting an inner spacer into the toelink aperture from the inner side of the hub; inserting an outer spacerinto the toe link aperture from the outer side of the hub; inserting abolt through the aperture of a tie rod end and through the apertures ofthe outer and inner spacers, respectively, wherein the relativediameters of the inner and outer spacers corresponds to the diameter ofthe bored toe link aperture of the hub and the relative diameters of theapertures of the outer and inner spacers are the same as the diameter ofthe toe link aperture; and securing the bolt with a nut.

In some embodiments, the toe link aperture has been damaged such thatthe toe link aperture is out of round prior to boring the toe linkaperture. In some embodiments, the method further comprises removing adamaged bolt from the toe link aperture.

The foregoing and other features and advantages of the present inventionwill be apparent from the following more detailed description of theparticular embodiments of the invention, as illustrated in theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconnection with the Figures, wherein like reference numbers refer tosimilar items throughout the Figures, and:

FIG. 1 is an exploded view of a toe link support, according to anembodiment;

FIG. 2 is a perspective view of a toe link support, according to anembodiment;

FIG. 3 is a section view of a toe link support, according to anembodiment;

FIG. 4 is an exploded view of a toe link support, according to analternative embodiment;

FIG. 5 is a perspective view of a toe link support, according to analternative embodiment;

FIG. 6 is a section view of a toe link support, according to analternative embodiment; and

FIG. 7 illustrates a method of supporting a toe link, according to anembodiment.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As discussed above, embodiments of the present invention relate tovehicle suspension systems and particularly to a support for a toe link.

The term “hub”, as used in this application, may refer to a “knuckle”,“spindle”, or “uprights” of a vehicle suspension system, and may be usedinterchangeably with those terms.

Conventional hubs comprise a toe link aperture with a diameter thatcorresponds to the diameter of a toe link bolt inserted therethrough.Conventional toe link bolts are in single shear, with forces in the toelink bolt, resulting from movement of the toe link acting on the toelink bolt, being counteracted only by contact of the toe link bolt withthe hub at the inner surface of the toe link aperture. This oftenresults in the toe link aperture being worn out or wallowed out, such asbeing ovaled out, cone shaped, or the like, by contact with the toe linkbolt, leaving the toe link aperture out-of-round. The toe link bolt isoften thereby left fitting loosely in the toe link aperture. The toelink bolt is also commonly damaged thereby by bending or breaking.Often, a hub may be further damaged by contact with the toe link and/orby contact with the nut. The hub may be made of a metal that is subjectto bending, or such damage as described above by contact with a toe linkor a toe link bolt or nut, such as aluminum, for example.

In embodiments of a toe link support 10 of the present invention, asshown in FIGS. 1-6, the toe link aperture 14 of the hub 12 may have beenbored out to correct any prior damage to the toe link aperture 14. Thetoe link aperture 14 may thereby have a larger diameter that is suitablefor receiving a pair of inner and outer spacers 16 and 30, wherein thediameter of the toe link aperture 14 corresponds to the diameters of thefirst ends 18 and 32 of the inner and outer spacers 16 and 30. In someembodiments, the inner and outer spacers 16 and 30 may be made of ametal that is resistant to bending, or such damage as described above bycontact with a rod end 50 or a toe link bolt 44 or nut 46, such asstainless steel, for example.

In embodiments, a toe link support 10 comprises an inner spacer 16 andan outer spacer 30, as shown in FIGS. 1-3. The inner spacer 16 may be ofsubstantially cylindrical shape having opposed first and second ends 18and 20, with the second end 20 thereof having a flange 26 thereabout,wherein the first end 18 thereof is inserted into the toe link aperture14 of the hub 12 from the inner side 6 of the hub 12. Insertion depth ofthe inner spacer 16 into the toe link aperture 14 of the hub 12 may belimited by engagement of the flange 26 thereof with the inner side 6 ofthe hub 12. The inner spacer 16 further comprises a longitudinalaperture 24 therethrough, the aperture 24 being configured to receive atoe link bolt 44 therethrough.

The outer spacer 30 may likewise be of substantially cylindrical shapehaving opposed first and second ends 32 and 34, with the second end 34thereof having a flange 40 thereabout, wherein the first end 32 thereofis inserted into the toe link aperture 14 of the hub 12 from the outerside 8 of the hub 12. Insertion depth of the outer spacer 30 into thetoe link aperture 14 of the hub 12 may be limited by engagement of theflange 40 thereof with the outer side 8 of the hub 12. The outer spacer30 similarly further comprises a longitudinal aperture 38 therethrough,the aperture 38 being configured to receive a toe link bolt 44therethrough.

In some embodiments, the first end 18 of the inner spacer 16 engages thefirst end 32 of the outer spacer 30. In other embodiments, the first end18 of the inner spacer 16 and the first end 32 of the outer spacer 30are separated by a gap.

In embodiments, as shown in FIGS. 1-3, a toe link bolt 44 may beinserted through an aperture 58 in a rod end 50, through the apertures38 and 24 of the outer and inner spacers 30 and 16, respectively, andsecured by a nut 46. In such embodiments, the hub 12 is protected fromcontact with the nut 46 by the inner spacer 16 and the flange 26thereof. The hub 12 is similarly protected from contact with the rod end50 by the outer spacer 30 and the flange 40 thereof. The hub 12 is alsoprotected from contact with the toe link bolt 44 by the inner and outerspacer 30.

Because the inner and outer spacers 16 and 30 may be made of a materialthat is more resistant to damage than the material the hub 12 is madeof, the inner and outer spacers 16 and 30 may be less susceptible todamage by contact with the toe link bolt 44, the nut 46, and the rod end50. In addition, because the toe link aperture 14 of the hub 12 has beenbored to a larger diameter than the diameter of the toe link bolt 44,such that the diameter of the toe link aperture 14 corresponds to thediameter of the inner and outer spacers 16 and 30, forces of the spacers16 and 30 acting on the inner surface 4 of the toe link aperture 14,resulting from motion of the rod end 50, are dissipated over a largersurface area to the hub 12 than the smaller surface area of the smallerdiameter conventional toe link aperture that is in direct contact withthe toe link bolt. This results in a much lower possibility of damage tothe hub 12 than with conventional systems.

In some embodiments, as shown in FIGS. 4-6, a second end 34A of theouter spacer 30 may extend beyond a flange 40A, wherein the flange 40Ais disposed about a middle portion thereof between the first end 32 andthe second end 34A, such that the outer spacer 30 may also be insertedinto an aperture 58 of the rod end 50. In addition, the flange 40A mayhave a tapered portion 41 extending therefrom toward the second end 34A.In such embodiments, the rod end 50 may be configured to be fitted withinner and outer high misalignment spacers (inner high misalignmentspacer not shown) and, the outer high misalignment spacer 56 beinginserted into the aperture 58 of the rod end 50 from the outer side 62of the rod end 50, and the second end 34A of the outer spacer 30 beinginserted into the aperture 58 of the rod end 50 from the inner side 60of the rod end 50. The tapered portion 41 of the flange 40A may therebyseparate the rod end 50 from the hub 12 to allow freedom of motion ofthe rod end, thus preventing contact of the rod end 50 with theoutermost edge of the flange 40A and the hub 12. In such embodiments,the inner high misalignment spacer on the tie rod end 50 is discarded,having been replaced by the second end 34A of the outer spacer 30 of theinvention.

In some embodiments, the second end 34A of the outer spacer 30 engagesthe outer high misalignment spacer 56. In other embodiments, the secondend 34A of the outer spacer 30 and the outer high misalignment spacer 56are separated by a gap.

FIG. 7 illustrates a method 70 of supporting a toe link comprising:boring the toe link aperture of a hub (Step 72); inserting an innerspacer into the toe link aperture from the inner side of the hub (Step74); inserting an outer spacer into the toe link aperture from the outerside of the hub (Step 76); inserting a bolt through the aperture of atie rod end and through the apertures of the outer and inner spacers,respectively, wherein the relative diameters of the inner and outerspacers corresponds to the diameter of the bored toe link aperture ofthe hub and the relative diameters of the apertures of the outer andinner spacers are the same as the diameter of the toe link aperture(Step 78); and securing the bolt with a nut (Step 80).

In some embodiments of the method, the toe link aperture has beendamaged such that the toe link aperture is out of round prior to boringthe toe link aperture. In some embodiments, the method furthercomprising removing a damaged bolt from the toe link aperture.

The embodiments and examples set forth herein were presented in order tobest explain the present invention and its practical application and tothereby enable those of ordinary skill in the art to make and use theinvention. However, those of ordinary skill in the art will recognizethat the foregoing description and examples have been presented for thepurposes of illustration and example only. The description as set forthis not intended to be exhaustive or to limit the invention to theprecise form disclosed. Many modifications and variations are possiblein light of the teachings above without departing from the spirit andscope of the forthcoming claims.

1. A method of supporting a toe link comprising: boring the toe linkaperture of a hub; inserting an inner spacer into the toe link aperturefrom the inner side of the hub; inserting an outer spacer into the toelink aperture from the outer side of the hub; inserting a bolt throughthe aperture of a tie rod end and through the apertures of the outer andinner spacers, respectively, wherein the relative diameters of the innerand outer spacers correspond to the diameter of the bored toe linkaperture of the hub and the relative diameters of the apertures of theouter and inner spacers are the same as the diameter of the toe linkaperture; and securing the bolt with a nut.
 2. The method of claim 1,wherein the toe link aperture has been damaged such that the toe linkaperture is out of round prior to boring the toe link aperture.
 3. Themethod of claim 1, further comprising removing a damaged bolt from thetoe link aperture.